Tekuami

FACULTY OF TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING
HOISTING COMPANY :-GOGO INDUSTRY PLC.
DURATION OF INTERN SHIP:- FROM MARCH 01 - JUNE 30, 2017
NAME:-ABAYENEW MULUYE
ID No Eng(R)0004/06
ADVISOR NAME:-Mr. SRINIVAS K.R.

SUBMISSION DATE:-16 OCTOBER 2017 G.C
DEBRE TABOR,ETHIOPIA
DTU INTERNSHIP REPORT &PROJECT
DECLARATION
This is to certify that this REPORT is an original work of ours and is being submitted in partial
fulfillment for the INTERNSHIP during the last four months. This report has not submitted
earlier either to this university or to any other University or Institute for the fulfillment of the
requirement of a course of study.
All relevant resources of information used in this paper have been duly acknowledged.
Name of student Signature Date
_______________ ____________ ____________
This is to certify that the above statement made by the candidate is correct to the best of
my knowledge and belief. This report has been submitted for presentation with my
approval.
Name of Mentor Signature Date
--------------------------- ----------- ---------------------
Name of Supervisor Signature Date

--------------------------------------- ------------------- -----------------
I
PREPAIRED BY:-ABAYNEW MULUYE MED 2017/18GC
Acknowledgement
It’s obvious that beside this kind of successful report, there should always be the help of
almighty GOD and some individuals who are generous and humbled. So, we forward our first
acknowledgement for almighty GOD for making everything possible. Although, I would like to
acknowledge our advisor Mr.Sirinivas for his un forgotten support and our host company’s
advisor Mr. Fekade, for his courage all the way to accomplish practical services and for our
report, in addition, it’s our pleasure to say thanks to the university’s industry leakage office for
insist this fortunate opportunity which enables us to engage with a lot of practical knowledge and
made us friendly with the industrial environment.
At last but not least, we would like forward our acknowledgement to the whole employees of
the hosted company (GOGO Industry) for their friendly attribute and appreciation throughout.
II
AN EXCEUTIVE SUMMERY
This internship paper includes the four months of my apparent ship work that deals with the
progressive task with the experienced and effective practical work. This consists of the
background history of the company (the origin and beginning organization of my hosting
company), overall experience that I got from the internship (things that I experience in and out of
the project that has been during the apparent ship season and that has to be recommended and
suggested , my main project (selection and analysis of efficient, better performing and good
capacity air tank), over all benefit that I gain from the internship(in terms of different aspects like
getting practical skill and theoretical knowledge) and final conclusion with recommendation
III
1. Table of Contents
DECLARATION ....................................................................................................................................... I
Acknowledgement ................................................................................................................................... II
AN EXCEUTIVE SUMMERY .............................................................................................................. III
CHAPTER ONE ........................................................................................................................................... 1
1 Background of the hosting company .................................................................................................... 1
1.1 Brief history .................................................................................................................................. 1
1.2 Vision of the company .................................................................................................................. 2
1.3 Mission of the company ................................................................................................................ 2
1.4 Goal of the company ..................................................................................................................... 2
1.5 The main products /services of GoGo Industry ............................................................................ 2
1.6 The main Customers of Gogo Industry ......................................................................................... 2
1.7 Organizational structure of GoGo Industry .................................................................................. 3
CHAPTER TWO .......................................................................................................................................... 6
2 How do I get into the company? ........................................................................................................... 6
2.1 Sections that I have been working in the company ....................................................................... 6
2.2 Work flow of the section............................................................................................................... 6
2.2.1 Cap production .......................................................................................................................... 6
2.2.2 Preform production area........................................................................................................ 9
2.2.3 Bottle production area ......................................................................................................... 12
2.3 Work tasks that I have been executed ......................................................................................... 15
2.4 Procedures that I have been used while performing tasks .......................................................... 15
2.5 Challenges while performing tasks ............................................................................................. 15
2.6 Measures that have been taken in order to overcome the challenges.......................................... 16
CHAPTER THREE .................................................................................................................................... 17
3 Benefits that get from the internship ................................................................................................... 17
3.1 In terms of improving my practical skill ..................................................................................... 17
3.2 In terms of upgrading my theoretical knowledge ....................................................................... 17
3.3 In order to improving Inter personal communication skill ......................................................... 17
3.4 In terms of improving team playing skills .................................................................................. 18
3.5 In terms of improving leadership skill ........................................................................................ 18
3.6 In terms of understanding about work ethics issues.................................................................... 18
3.7 In terms of entrepreneurship skill ............................................................................................... 19
IV
PART TWO ................................................................................................................................................ 20

PROJECT TASKS ...................................................................................................................................... 20
CHAPTER FOUR....................................................................................................................................... 20
4 DESIGN AND DEVELOPMENT OF BELT CONVEYOR .............................................................. 20
4.1 INTRODACTION ...................................................................................................................... 20
4.1.1 Background of Belt Conveyor ............................................................................................ 21
1.3.StatementofProblem ...................................................................................................................... 22
4.1.2 Objective Of the Project ...................................................................................................... 22
4.1.3 Scope of Project .................................................................................................................. 23
4.1.4 Limitations .......................................................................................................................... 23
CHAPTER FIVE ........................................................................................................................................ 24
5 LITERATHERE REVIEW ................................................................................................................. 24
5.1 CONVEYOR SYSTEM.................................................................................................................. 24
5.1.1 BELT CONVEYOR ........................................................................................................... 26
CHAPTER SIX ........................................................................................................................................... 29
6 Methodology ....................................................................................................................................... 29
6.1 Primary methodology.................................................................................................................. 29
6.2 Secondary methodology.............................................................................................................. 29
6.3 Design specifications .................................................................................................................. 31
6.4 MATERIAL SELECTION ......................................................................................................... 32
6.4.2 Selection of Belt and Criteria of Selection .......................................................................... 35
CHAPTER SEVEN .................................................................................................................................... 37
7 DATA ANALAYSIS .......................................................................................................................... 37
7.1 Analysis of Belt Dimension, Capacity and Speed ...................................................................... 37
7.1.1 Belt Speed ........................................................................................................................... 37
7.1.2 .Belt Capacity ...................................................................................................................... 37
7.1.3 Belt Tension ........................................................................................................................ 40
7.1.4 .Design of Roller ................................................................................................................. 43
7.1.5 Design of Driving Belt ........................................................................................................ 44
7.1.6 Determination of Power and Motor Selection .................................................................... 47
7.1.7 Design of Shaft.................................................................................................................... 51
7.1.8 Selection of Bearing ............................................................................................................ 56
7.1.9 Selection of Key .................................................................................................................. 61
V
CHAPTER EIGHT ..................................................................................................................................... 64

8 RESULT AND DISCUSSION ........................................................................................................... 64
8.1 Result .......................................................................................................................................... 64
8.2 Discussion ................................................................................................................................... 64
8.2.1 COST ANALYSIS OF THE BELT CONVEYOR ............................................................. 65
8.2.2 PART AND ASSEMBLING DRAWING .............................................................................. 65
CHAPTER NINE ........................................................................................................................................ 77
9 CONCLUSION AND RECOMMONDATION ................................................................................. 77
9.1 Conclusion ...................................................................................................................................... 77
9.2 Recommendation ........................................................................................................................ 77
REFERENCES ....................................................................................................................................... 79
Appendix ................................................................................................................................................. 80
LIST OF TABLES
Table 1 the temperature, pressure and speed values of cap production process. 9
Table 2 control parameter of the barrel heater, mold heater, inject and open/ close clamp values in
perform production. ................................................................................................................................... 12
Table 3 the parameters or operating conditions in the process production of bottle ............................... 14
Table 4 material to be conveying ................................................................................................................ 31
Table 5 mechanical properties of conveyor roller material........................................................................ 32
Table 6 the mechanical properties of pulley material ............................................................................... 33
Table 7 mechanical properties of shaft material......................................................................................... 33
Table 8 mechanical properties of bearing material ................................................................................... 34
Table 9 mechanical properties of belt materials. ....................................................................................... 34
Table 10 designation and characteristics belt yarns ................................................................................... 35
Table 11 belt class and its mass cover thickness ........................................................................................ 36
Table 12 mass of the moving parts ............................................................................................................ 41
Table 13 application and life of bearing..................................................................................................... 57
Table 14 Xand Y factors for ball bearing ..................................................................................................... 58
Table 15 dimension and static and dynamic load capacity of ball bearing ................................................ 58
Table 16 end condition and the relation between effective length and actual length ............................. 62
Table 17 cost of conveyor parts ................................................................................................................. 65
Table 18 part name ...................................................................................................................................... 76
LIST OF FIGURS
Figure 1:- General Organizational structure of Gogo Industry ..................................................................... 3

Figure 2 process step diagram of cap, perform and bottle production........................................................ 5
VI
Figure 3 Diagram of cap injection machine .................................................................................................. 7

Figure 4 ......................................................................................................................................................... 8
Figure 5 Process of cap production............................................................................................................... 9
Figure 6 preform injection machinery .......................................................................................................... 9
Figure 7General flow diagram of Preform Injection Machine .................................................................... 10
Figure 8 flow drawings for perform production line ..................................... Error! Bookmark not defined.
Figure 9 Process of Perform production ..................................................................................................... 11
Figure 10 Products of perform injection machine ......................................... Error! Bookmark not defined.
Figure 11 The mold Structure of perform injection machine ................................................................... 12
Figure 12 the structure of bottle ................................................................................................................ 12
Figure 13 Diagram ofblowing machine ....................................................................................................... 13
Figure 14 Process of Bottle production ...................................................................................................... 14
Figure 15 ..................................................................................................................................................... 24
Figure 16Belt conveyor transportation of ores and other packed product................................................ 25
Figure 17 Belt conveyor, circa 1954(photo courtesy of modern group) .................................................... 26
Figure 18 Belt conveyor systems ................................................................................................................ 26
Figure 19 rotating elements, flow direction and cross sectional area of belt conveyor .... Error! Bookmark
not defined.
Figure 20 conveying belt ............................................................................................................................. 35
Figure 21 ..................................................................................................................................................... 39
Figure 22 AC permanent magnet servo motor ........................................................................................... 47
Figure 23 Radial ball bearings and housing ................................................................................................ 57
Figure 24 bearing cap.................................................................................................................................. 60
Figure 25 frame of conveyor ....................................................................................................................... 63
VII
I
CHAPTER ONE
1 Background of the hosting company

1.1 Brief history
The factory of Guna spring water plc was inaugurated in Arega Keble peasants association
near Kemer Dengay Town of Farta Wereda in South Gondar zone, Amhara regional state, on
Saturday, February 26, 2011.
The factory, which initially started trial production of 500ml, one-litter, and 1.8 liter bottles in
January, has a production capacity of 144,000 liters per day and 52.6 million liters per year.
Since commencing production for commercial purposes, also in January, the product range has
expanded to include 3330ml and two-liter bottles, according to Adebabay Birru, general manager
of gogo industrial plc, which established the company.
With Guna factory becoming operational, the number of bottled water brands has increased to
seven, since the introduction of the product in the country with high land spring by Apex bottling
company,of the total guna is situated at the highest altitude; this will make the water the best, to
date, claimed Adebabay. Initially the owners had their eye on the area around Dashen Mountain,
the tallest mountain in the country, located in the same region, but decided on guna after testing
its water, he claimed further.
“Ours will be better than all the water in Ethiopia,” he told fortune. “We are going to compete
internationally.”
Gonder, Gojjam, Wello, Humera and Metema towns, located in the northern part of the country,
as well as Sudan and Djibouti are target destinations for the water, Adebabay told fortune.
The factory has also constructed potable water and laundry facilities as well as drinking facilities
for animals in two areas of the kebele where it is located, according to Wale Ayehu, chief of
Farta wereda. The factory is the largest investment for the wereda and zone, he said.
“Hotels are the more usual investment but this is the eyes breaker and will prove to other
investors that the area is suitable for investment,” Wale told fortune.
The new entrant to the bottled water market was established with a capital of 20 million Br in
2006. However the capital was later increased to 30 million Br due to the increasing prices of
construction materials and machinery imported from china where they were produced using
Japanese technology according to Adebabay.
The total investments of 30 million birr covered the construction of the factory on a 30,000 sq.m
plot and include the machinery and inputs.
Guna spring water, which is located 32km and 45km from Debretabor town of south Gonder
1
PREPAIRED BY:-ABAYNEW MULUYE MED 2017/18G.C
zone and Nefas mewcha town of lay gayint woreda, respectively. Pays 0.25pc of its profits in
royalties to the ministry of mines (MOM). The three springs from where the water is obtained
are situated two kilometers from the factory, on Guna Mountain, for which the company is
named.
During the war between EPRDF and Derg, the former had lost many soldiers in the mountain,
the third highest in the country at 4,231 meters. Members of the EPRDF have also named a
company, Guna Trading House plc, after the mountain.
Another company constructing a bottled water factory in Laygayint Wereda near the mountain
had applied for the use of the name, but Guna was first according to Alemseged Shiferaw,
process owner of developmental investors work for the zonal trade and Urban Development
Bureau.
1.2 Vision of the company

GoGo Industry wants to improve its production capacity by using modernizing and latest
controlling systems. As well as this industry tries to open other branches in order to produce soft
drinks like Pepsi, Coca cola, and Mirinda.
1.3 Mission of the company

GOGO Industry becomes one of the leading industries for the production of good quality of
water; that is suitable for human being.
1.4 Goal of the company

The main goal the company is performs its task by satisfying the demand and supply of the
customers and competitive in market to must be profitable. Every company has vision and
mission but to attain their vision and mission the installation must have a goal that will be
changed with time at progress. As every company PLC has a vision of becoming at international
installation to participate in the poverty reduction process.
1.5 The main products /services of GoGo Industry

There are products or services that manufactured or produced from GoGo Industry. These
products that manufactured in the industry are also available for customers in different
directions. Those products that are produced in this industry are listed below.
 Cap production
 Bottle production (0.5 liter, 1 liter .and 2 liter).
 Soft and spring water production.
1.6 The main Customers of Gogo Industry

The main customers in the products of this company are North Gondar ( around metema,
humera, Abderafi),different parts of South Gondar, different parts of East Gojam, different parts
of West Gojam, different parts of North Shewa and many shops that found in different Towns of
the country. The company also has a plane to export the products to the countries that found
2
around Ethiopia like Sudan and Djibouti.
1.7 Organizational structure of GoGo Industry

Organizational structure refers to the way that an organization arranges people and jobs so that
its work can be performed and its goal can be met.
The organizational structure of Gogo Industry is classified as in to different branches or
departments to facilitate its work. This different branches or departments are:- production
department, maintenance and engineering department, Warehouse and material planning
department, quality control department, purchasing and supply department, quality assurance
department, research and development department, human resource managing department,
finance and budgeting or accountant department and marketing and selling department. All this
branches or departments play their own role on improving the productivity of the company. The
organizational structure is shown the figure bellow.
chief executeve
production
human resource department department
head head
qulity
production
control control technitian
departme department
depaartment
nt
chief
secretary finance store
officer
Casher purchaser mecha chemic electrical

nical al
Figure 1:- General Organizational structure of Gogo Industry

Each department has its own role to improve the production capacity of the company. The work
flow of the company or the work flow of the Organizational structure that drowns above is
3
shown below:-
General Manager (GM):- Controls each and every activities of the company that performed in
each department.
 Quality Control Management (QCM):- Controls or checks the quality of raw materials
and products of the factory. Quality control personal shell carries the following activities
per minimum recommended frequency.
 Quality assurance department :-insures or checks the standardized qualification of raw
materials and it classifies for the checked raw materials as approved and rejected. The
rejected raw materials are not satisfied the required quality and these rejected raw
materials are stored in the rejection area until another measurement is taken. And the
approved raw materials are satisfying the required quality. These raw materials are send
in to wear house department and then this ware house department receives these
approved row material and send to production department based on this department
requisition form.
 Production Management (PM):- Manages and controls the total amount of production
in the company. The production department also receives the approved raw material that
checked by quality control and divides them in to each production line to be converted
into a required product. The production department sends the finished products into ware
house and this ware house department provides the finished products in to marketing
department.
 Maintenance and Engineering Department (MED):- - Exercise the maintenance
activities of the company. Engineering departments such as electrical, mechanical and
chemical engineering has enough workshops with technological maintenance machine
and enough spare parts store.
 Human Resource Management (HRM):- Works depending on the requirements of
labor force of the company.
 Finance Management (FM):- Performs financial analysis in the company. Different
branches also can be exists in this department to perform correct financial analysis in the
factory. These includes:-
-Purchaser: - Purchases the appropriate raw materials that used for the production of the
required products, from the suppliers of the company. In addition to this, the purchasing
department supplied the purchased raw materials in to store.
-Casher OR Seller: - Sells the product in to customer, which produced from the company.
Note: - Each activities of each department perform with standard requisition by the chain of
activities of the company to facilitate its work. The company has enough permanent workers that
work in each department and they earn their salary based on their profession and work strength.
When the company profit is too much sometimes the workers earn double salary at the end of the
year.
1.8Generalworkflowofthecompany
4
Bottle production part :-The raw material PET is mix from masture batch color by vertical
mixer ,then using loader transport in to plastic injection molding machine ,which produce
performs. After this process ,we heat the perform using the blowing heater finally this heating
performs go to blowing machine these machine stretch the pre form and the bottle are produced.
Figure 2 process step diagram of cap, perform and bottle production

.
5
CHAPTER TWO
2 How do I get into the company?

In 2008 E.C at the end period of second semester Debre Tabor University department of
mechanical engineering informed me to take internship placement form prepared by university
industry linkage. The form was given to me to find internship hosting company. Then I choose
GoGo Industry, because it is relating to my field of study. After I choose this industry, I gave the
internship application paper to the company that I receipt from the university. After that, I
discuss with the manager as well as mentor and start my internship and continue to perform the
practical education. In general, with many ups and downs I spend a 4 month internship period at
GOGO industry from March to June 2009 E.C.
2.1 Sections that I have been working in the company

In GOGO industry,I try to work in all sections.especially in cap injector machine ,preform
injector machine,bottle blowing machine,filling machine and capping machines.
2.2 Work flow of the section

2.2.1 Cap production
2.2.1.1 Raw material of cap production
The raw materials used for cap production are:-
-HDPE or High Density polyethylene
-LDPE or Low Density Polyethylene
-Master Batch (color concentrate).
-crushed material.
-defective caps can be shredded and can be used as raw material.
*Not: - in the cap production process the above three raw materials i.e. HDPE, master batch and
crushed material must be mixed until uniformity reach.
2.2.1.2 Equipment’s used for cap production
In cap production area by using the machine that drawn bellow. it is possible to produce different
sizes by changing the mold of the machine.
6
Figure 3 Diagram of cap injection machine

The equipment’s used for cap production from the given raw material are:-
General name of this machine is known as cap plastic molding or injection machine. Then this
cap plastic molding machine consists of the following components.
*Mixer:-Used to combine or mix the raw materials of cap i.e. HDPE, Master Batch and crushed
martial until uniform distribution exist in the mixture.
*Hopper: - Used to melt the raw materials that mixed uniformly in the mixer.
* Mold Heater: - Used to heat the mold to produce the cap in the required shape. It have
thermocouple sensor.
*Solenoid: - They are electrical parts or rectified circuits used to convert alternative current in to
direct current.
*Pump: - Sack oil and then push the melted raw material into hose.
*Valve: - Two types of valves are existing in this machine. These are:-
1, Relief valve:-the valve used for the general control of the machine.
2, Directional valve: - used to control specific operation of the machine.
The above two valves are different in size of valve, the function they perform and number of
coil.
The cap plastic molding machine is made of three basic things. These are:-
 hydraulic system or hydraulic oil
 mechanical part and
 electrical part
Functional only if both three things are exist and it is programmed with assembly language to
perform these three things in one function.
2.2.1.3 Process of cap production
When we manufacture the caps in process industries it follows the following general cap
production procedure.
7
Mix HDPE, master

Switch on the batch and
Weight 5kg HDPE Clamp the mold
mixer (2) recycled materials
16G master batch at specified load
& 10% of crush (3)
of tonnage (4)
material (1)
Check air & cooler Set parameters Heat the mixer Feed the mixed
water lines are for materials to materials for 30 material in to
functional and be plasticized minutes (6) hopper (5)
switch on the in the feeder
system (8) (7)
Start injecting the Sample and

Recorded the
molten material in to inspect caps (11)
number on the
the closed mold (10)
production counter
or set to zero at start
up(9)
Weight cats that pass Yes Weight and segregate

inspection (13) Does cap pass No defective caps (16)
inspection (12)?
Shared defective items use

as raw materials (17)
The caps that pass

inspection shall be Keep caps in container ready
sheltered on the for delivery (15) At shift end, record the production
Figure(14).
sheltering machine 4 quantity on the machine counter
and complete daily production (18)
()(18)record (18)
8
Figure 5 Process of cap production

In the process of cap production or cap injection molding the temperature, pressure and speed
values are set as follows.
Table 1 the temperature, pressure and speed values of cap production process.
inject pressure 50-7 5Mpa

inject speed 50-75m/s
clamp open/close pressure 70-90Mpa
Clamp open/close speed 80-90m/s
barrel heater temperature 220-250OC
2.2.2 Preform production area

2.2.2.1 Raw material of Preform production
The raw materials used for perform production are:-
 PET or polyethylene Terephthalate.
 Master batch (color concentrate).
 defective perform shall be shredded and used as raw materials.
 Defective bottle shall be shredded and used as raw material of perform production.
 PET is polymer that is formed by combining two monomers called modified ethylene
glycol and purified tetra phthalic acid.
*Note:-PET is stronger than HDPE to form chemical change by using heat i.e. PET needs high
heat compared with HDPE. But the size of PET is smaller than that HDPE.
2.2.2.2 Equipment’s used for Preform production
Figure 6 preform injection machinery
9
Figure 7General flow diagram of Preform Injection Machine

General name of this machine in Fig2.3 is known as perform molding or perform injection
machine. Then these preform molding machine consists of the following components:-
 Mixer:-Used to combine or mix the raw materials of perform i.e. PET, Master Batch and
crushed martial until uniform distribution exist in the mixture.
 Sacking Machine: - Used to sack uniformly mixed raw materials from the mixer in to
hopper.
 Compressor: - Used to compress the preform in to required shape and size.
 Hopper: - Used to melt the raw materials that mixed uniformly in the mixerMold Heater:
- Used to heat the mold to produce the preform in the required shape. It have
thermocouple sensor
 Pneumatic: - Used to remove additional part that exist in the preform.
 Loader:-Used to sack air from the environment.
 Industrial Cooler or Chiller: - Used to cool the water that exist in the hopper machine.
The preform molding machine is made of four basic things to perform its function correctly.
These are:-
 hydraulic system or hydraulic oil
 mechanical part
 electrical part and
 pneumatic
Functional only if all four things are exist and it is programmed with assembly language to
perform these four things in one function.
Note: - The perform molding or perform injection machine needs an energy of 72KW/hr.
Process of Preform production
10
The working principle of perform injection machine is the same as cap injection machine. When
we manufacture the preform in process industries it follows the following general perform
production procedure or PET preform injection molding.
Weigh PET resin and master Switch on the

Mix PET resin, master
batch in ration of 100kg to 6g hopper and
batch and recycled
or in ratio of 99.99% of resin mixer (2)
material (3)
to 0.01% of master batch.(1)
Set control parameter

Heat the mixed Feed the mixer
of the baffle, mold,
material for four into hopper (4)
and heater, inject and
hours (5)
open close lamp (6)
Check air and Start injecting the

Record the cooler waters are molten material into
number on the functional (8) the closed mold (9)
production
counter or set to
zero at start up (7)
Does perform Inspect the PET

NO
pass inspection? perform (10)
(11) Yes
Keep performs in
Weigh perform container ready for
that pass stretch blow molding (15)
inspection (14)
Weigh and segregate the
defective perform (12)
Shred defective Record the number on the machine

items to use as counter at shift end complete daily
raw material production record (16)
11
Figure 8 Process of Perform production
In the process of perform production or perform injection molding the control parameter of the
barrel heater, mold heater, inject and open/ close clamp values are set as follows.
Table 2 control parameter of the barrel heater, mold heater, inject and open/ close clamp values
in perform production.
0.5L 1L 2L
/ Inject pressure (MPa) 30-60 30-65 30-60
Inject speed (m/s) 30-60 30-60 30-60
Barrel heater temperature (oC) 280-320 280-320 280-320
Mold heater (.) 209-211 230 270
Open/close clamp pressure (MPa) 65-70 55-65 65-70
Open/close clamp speed (m/s) 70 70 70
Figure 9 The mold Structure of perform injection machine
2.2.3 Bottle production area

2.2.3.1 Raw material of Bottle production
Bottle is a container with a narrow neck, for storing liquids. Its structure seems like as follow:-
Figure 10 the structure of bottle

The raw materials used for bottle production are:-
12
-performs that produce from PET.

2.2.3.2 Equipment’s used for Bottle production
The structure of bottle injection machine or blowing machine shown below.
Figure 11 Diagram ofblowing machine

The equipment’s used for bottle production from the given raw material are:-
General name of this machine is known as bottle molding or bottle injection machine. Then this
bottle molding machine consists of the following components
*Air Dryer:-Used to dray the moisture that exist in the air.
*Condenser: - Used to condense the water that comes from the environment.
*Blowing Machine: - Used to blow the preform to produce the bottle with required shape and
size. In this blowing machine Pneumatic System is performed in the way of, as the piston gets air
from air compressor machine, the piston closed and down ward and stretch the preform in to the
desired shape and we get bottles. After some time the piston moves up ward and opens. Until the
air is get in to the piston, the whole process of bottle production carried out in such away.
In this machine air come in to two ways.
1. High pressure:-Used to stretch and form the required shape.
2. Low pressure:-used for moment of everything that exist in the machine.
In the case of High pressure clean air is need. Because the preform is blow by using air with
blowing machine. Then this air used to prevent the existence of odor in the bottle.
2.2.3.3 Process of Bottle production
When we manufacture the bottle in process industries it follows the following general bottle
production procedure or stretch blow molding.
13
Preheat performs
Switch the
in the revolving Open the mold
revolving
pre heater (2) insert pre heater
preheated
(1) perform (3)
Allow the bottle

Open mold and
to cool for Blow air in to
eject bottle (6)
solidification. (5) the perform
(4)
Inspect NO
bottle (7) Bottle pass Segregate defective
Inspection (8) Items and Count the
amount. (10)
YES
Shred defective
Place in package Measure or count the items to use as raw
ready for filling. volume of bottles material. (12)
(11) manufactured. (9)
Figure 12 Process of Bottle production

In the process production of bottle in industry the parameters or operating conditions can be
adjust in the following way for three type of liter i.e. for 0.5L ,1L and 2L.
Table 3 the parameters or operating conditions in the process production of bottle
0.5L 1L 2L
Temperature (co) 92 95 100

Speed (m/s) 12.1 11.2-12 9.7-10
Cooling time (s) 5.6 7.2 7.3
Blow molding parameters are to be set as follows.
14
.high pressure: 2.0MPa

.low pressure: 0.8MPa
Note:- in the process production of bottle, cap and perform we proceed the following process
step diagram.
2.3 Work tasks that I have been executed

Some of the tasks that I executed were don’t have any relation with mechanical engineering
subject matters; I perform every activity in the section and were act as a laboratory technician, as
machine operator, as labor worker and so on. The tasks I were performed include the following
 Deciding which ratio of mixing would create the right color of cap, preform and bottle.
 Working out the right clean bottled water production method and correct procedures in
preform, cap and bottle production in the factory. However, the operation is always
performed with estimation.
 To see the sample preform and checking to make sure it produces the right results or the
required bottles.
 Recommending any special finishes or treatments to be applied after the production
process. For example if the content of chlorine is high when that check in the laboratory
section I give recommendation for chemists the spring must be cleaned for a long period
of time continuously.
 Searching different information’s about the works that perform in the laboratory section
and the problems that exist by the lack of wise use of equipment’s and chemicals and
analyzing their effects.
Sometimes I perform supporting tasks like:-
- Advising the Chemist in his or her administration work
- Informing the labors how they work with safety and precautions
2.4 Procedures that I have been used while performing tasks

During my internship seasons there are different procedures that I were follow to carried out my
tasks. From those procedures the following are included.
 First I accept any kinds of tasks from the supervisor, machine operator or the labors.
 Before performing any tasks I have agreed on what I have performed and then I have to
carefully analyze the tasks I operate.
 If I encountered any problems, immediately I ask any questions to my supervisor.
 After performing any tasks I report to my supervisor or machine operator.
Then they will check if the tasks are perfectly executed or not. Since the tasks that I have to
perform are always similar, there were no any errors in my works. That means always I have to
perform my tasks accurately.
2.5 Challenges while performing tasks

15
In every work place and time there are many challenges that are faced for every workers or it is
clear that any job will have challenges, similarly on my internship period I face different types of
challenges. The challenges are:-
 I spend the first month of my internship period by observation alone rather than active
participation in the company and there were not enough assigned works for me, thus I
were bored, underutilized and tempted to peruse Face book, sleeping, remembering the
life that I precede in the first semester by forgetting the activity and play other games.
 The company is mostly not in operation in my 4-month internship. I did not get the
chance to see all systems in operation.
 Every factory is design and erect with the cooperation of many engineer; like chemical,
electrical, mechanical, civil, instrumentation and other engineering fields.
 Communicating with the workers was one challenge for me, which means more of the
workers in the company are illiterate’s the words that they use to describe the work flow
were not easily understandable. So it was difficult to inter relate my theoretical
knowledge with the practical work.
The company has no information about what every internship student will have to do regarding
to their subject matters.
2.6 Measures that have been taken in order to overcome the challenges
 On the first month of the internship I perform labor works such as attaching a seal,
attaching label with bottle and put perform on the heater of blowing machine to not be
bored and to create a good working atmosphere with the workers.
 When the factory perform its operation I was attend from 2:00 o’clock up to 11:00
o’clock to see many operations in the process.
 I create a relationship with the other department workers and asking them about the
points that I need. During that time, there were challenges like not correctly told me the
information that I need. In addition, the information differs from one to the other. But it
were give the hint for me and comfortable to refer different sources.
 I explore additional information’s from internet to understand on what the illiterate’s
workers tells me about the work flow.
 I raise different questions to my advisor repeatedly on how things are done and I ask my
supervisor for additional work to do and I help him in his works.
16
CHAPTER THREE
3 Benefits that get from the internship

There are many benefits that were gain from the internship that are basic for my life. From those
the following are included.
 Improving Practical skill
 Upgrading theoretical knowledge
 Upgrading Inter personal communication skill
 Improving Team playing skill
 Improving Leadership skill
 Understanding about Work ethics issue, industrial psychology and related issues
 In terms of Entrepreneurship skill
3.1 In terms of improving my practical skill

In order to acquire practical knowledge, doing more practice is the only choice. Then by
participating in some departments of the company especially in production and Maintenance
departments I have improved my practical skill and I have learnt about working Process of the
departments. The internship period was a good opportunity for practical skill. I change my
pervious academic knowledge into practical work through this internship program. I improve
practical skills on operating machineries, proper use of chemicals and on analyzing samples.
3.2 In terms of upgrading my theoretical knowledge

Since the practice depends first on theory, it was somehow easy to correspond with the practical
work. Then from this I have learnt how to visualize my theoretical knowledge, how to relate it
with the Practical work of the company, and I have observed that which course in what process
of the Department should exercise and advantages of the courses in solving the problems of the
company. It is not very challenging to change the theory into practice. Theoretical knowledge is
dependable on principles, logics and calculations. It is interesting when the theoretical
knowledge & the practice meet exactly as you wanted to. Sometimes this relationship fails to
some degree. Theoretical knowledge doesn’t show you the tasks, which are processed in the
company. Generally speaking, our theoretical knowledge got strengthens more by those practical
techniques invested on the company. This is because we had to refer every time when we came
across a problem.
3.3 In order to improving Inter personal communication skill

Inter personal communication is the process by which people exchange information, feelings and
meaning through verbal and non-verbal messages. It is face to face communication. Therefore
Inter personal communication skills are developed or improved or enhanced with increased
knowledge and practice. During Inter personal communication, there is message sending and
message receiving. It is also essential to career success. Developing good Inter personal
communication skills allows a person to engage with others productively at different levels
17
3.4 In terms of improving team playing skills

During my internship, we were inducted as a team member and were assigned various activities
that had to be performed in a team. It taught us how activities are to be performed in a team and
impact of behavior of one on the work and performance of the other team member. The proper
team work lead to the whole benefits. On the contrary, loafing by some team members could lead
to huge negative impacts on the overall team performance. From these I learned the importance
of team work and some general skills required while working in a team, and also I have learnt
how to improve tolerance and team work with different workers of the Company even they have
different habit and skill.
3.5 In terms of improving leadership skill

I learn this critical management skill from this internship program. Now I have the ability to
motivate a group of people towards a common goal and I have got the experience of managing
labors and distributing them to their specific jobs. And also I have improved how can I feels a
strong leadership and how can I fulfill my leadership Skill honesty in every activities of the
company without any discrimination of work. I have also understand how to manage resources
and groups of workers, counseling, setting examples, planning and evaluation in addition I have
experience decision making ability, risk management and accepting and transferring work
orders.
3.6 In terms of understanding about work ethics issues

From this perspective I have gained valuable lesson that transparency and carefulness are two
very important work ethics one needs to abide and live. Similarly I improve the following work
ethics:-
 Cooperation- Every worker should interact and cooperate with each other while
working . I learnt that cooperation is the crucial way in solving problems easily and
wisely.
 Honesty- Regarding this value each worker regardless of its status should abstain
from bad behaviors such as cheating , bias , corruption etc..
 Punctuality: - arriving on time at work place was necessary. Since it was our task to
manage, control, monitor and supervise the portion of the dying class we have been
given. Sometimes we had to work late because it is our responsibility to accomplish the
started dying process. And also some works like machine cleaning, dye preparation
requires starting early and leaving the work late.
 Work place disciplines- in work place you don’t have to disturb the working
atmosphere. For example, you should have to restrain yourself from opening loud
music’s, songs and things which disturb other workers’ working mood, to switch your
phones when you work with machines and so on.
Therefore I have gained the advantages of ethical issues in work and I have learnt how to select
that, which ethical issues should participate in what work, and how to develop and how to fulfill
thus ethical issues.
18
3.7 In terms of entrepreneurship skill

Entrepreneurship is a key driver of economic growth and job creation. It provides many people
with career opportunities that better fit their preferences than waged employment.
After the completion of internship, we are more motivated to look forward in creating our own
share company with others. However, we were not in any way to experience this skill from our
company because the attention of every employer is not creating something new rather they
focus in performing their tasks alone.
19
PART TWO
PROJECT TASKS
CHAPTER FOUR
4 DESIGN AND DEVELOPMENT OF BELT CONVEYOR
4.1 INTRODACTION
Conveyor system is a common device of mechanical handling equipment that moves the
materials from one location to another location. Conveyors are especially useful in the
applications involving the transportation of heavy or bulk materials. Conveyor systems
allow quick and efficient transportation for a wide variety of materials, which make very
popular in the material handling and packaging industries. Many kinds of conveyors systems
are available, and applicable in Manufacturing and service industries [Alspaughm.A 2004].
Conveyors are able to safely to transport materials from one level to other, which done by
human labor would be strenuous and expensive. They can be installed almost in anywhere,
and are much safer than using other types of equipment, such as forklift or other machine
and manually to move materials. They can move loads of all shapes, sizes and weights and
also many have advanced safety features that help prevent accidents. There are so many
types of options available for running conveyor systems, including the hydraulic,
mechanical and fully automated system, and other drivers, which are equipped to fit
individual needs. The drivers are may be flexible and non-flexible drivers. The types of
flexible drivers are belt, chain and rope, the power is not directly transmitted, because of it
needs transmission link between the rotating parts. While the non-flexible drivers are gear
and they are not needs a connecting link between the rotating parts [Gupta.J.K.A2005]. But
most widely used in mechanical conveyor system in many types of industries such as
automotive, agricultural, computer electronic, food processing, aerospace pharmaceutical,
20
chemical, bottling and canning, print finishing and packaging. Although a wide variety of
materials can be conveyed, some of the most common including food items such as beans
and nuts, bottle and cans, automotive components, scrap metals pills and powders, wood and
furniture’s and grain and animals feed [Zazzal and EI-Nashar Ahmed 2007].
Many factors are important in the accurate selection and design development of conveyor
system. It is important to know how the conveyor system will be used beforehand. Some
individual areas that helpful to consider are the required conveyor operation, such as
transportation, accumulation, the material size, weight and shapes and where the loading,
unloading and pickup points need to be. [ESPEE LAGE.W 2003].
4.1.1 Background of Belt Conveyor

Before going to transport the material, it should be identify, which types of material to be
transported in a conveyor system. In any process and sites, the raw materials and products
need to be conveying from one process or stage to another [Ananthetal 2014]. Belt conveyor
is one of the common types of material handling equipment. It is designed such that
facilitate easy, cheap fast and safely loading and unloading with less human interference and
due to this reason the design can be ergonomically factor should be considered which is
human capability in terms of safety of operations weight and height. This paper is consider
with the design and development of a belt conveyor system in gogo industry plc. for the
transportation of bottles, because of the material handling system in gogo industry plc is
manually and there is no any types of conveyor system
Other types of material handling system rather than manual material handling in gogo industry
plc. The manual material handling system has so many negative feed backs, such as need high
efforts, costly, large number of labors, time consumption, reduced bottle’s quality, case of
conflict, and damage of bottle and injury of works. In order to reduce the above problems.
Therefore in this paper the design and Development of belt conveyer system in gogo industry
plc. is done. In this design for power transmission system a flat belt driver is connected to the
motor shaft pulley to the roller shaft pulley of the conveyor. It has more power transition
capacity high percentage efficiency than others. The arrangement
of the design conveyor is depending on the types of materials to be conveyed and the
maximum lump size of the materials. That is the materials to conveyed are non-packed and
fluid type, so the arrangement is horizontal with the slop is zero and it consists of three
21
impact idler, seven carrying idlers and four return idles based on the idle space length, an
endless and flexible belt of high strength with endless and pulley (drive and driven) at
affixed position supported by rollers. The driving units of this design, electric motor, pulley,
shaft and rollers and the other main parts are, belt, frame. The installation of the design
conveyor is two ways or dual which is forward and back ward conveying system, but the
design is only one. Because of the forward direction of the conveyor is used to transport the
services material and food items, from the washing and cooking room to flooding room
respectively. The back tracking movement of the conveyor is to return the above items to the
first rooms. The arrangements of the washing room and the cooking room must be near
to each other, to transport the service and food simultaneously. In this design, the material
characteristics to be conveying, maximum lump size, Belt conveyer efficiency, the belt
speed and capacity the belt tension, and the cost of the conveyer system is considered.
1.3.StatementofProblem
In gogo industry plc. for the transportation of bottle, because of the material
handling system in gogo industry plc. is manually and there is no any types of
conveyor system and other types ofmaterial handling system rather than manual
material handling in gogo industry plc.
The manual material handling system has so many negative feed backs, such as
need high efforts, costly, large number of labors, time consumption, reduced
bottles quality, case of conflict, and damage of materials and injury of works. So
that the design and development of belt conveyor system in gogo industry plc is
mandatory ,in order totackle the above problems. Therefore in this paper the design
and Development of beltconveyer system in gogo industry plc. is done.
4.1.2 Objective Of the Project
4.1.2.1 . General Objective
The general objective of the project is:-
Design and development of Belt conveyer system in gogo industry plc.
4.1.2.2 Specific Objective of The Project
The Specific Objective of The Project is:-
nyers.
22
4.1.3 Scope of Project

This project shows design of belt conveyor system.the detail design of the project is calculating
belt tension,belt capacity,design of bearing,design of key,design of shaft ,cost analaysis and part
and assembly drawing of belt convayor sysem .
4.1.4 Significance of the Project
 To minimize the transportation problem of gogo industry plc.

 To reduce the number of labor s and labor costs.
 To reduce the cost of materials.
 To keep the bottles quality.
 Avoidance of damage of service material and injury of workers.
 Reduced time consumption.
 Improve safe operations of workers
4.1.4 Limitations
 At the time of doing my project, there are many obstacles. Those are:-
 Lack of Internet connection
 Lack of reference books
 Shortage of materials and equipment
23
CHAPTER FIVE
5 LITERATHERE REVIEW
5.1 CONVEYOR SYSTEM
Conveyor system is afixed position, continuous flow and variable area or not restricted.
Conveyors are durable and reliable equipment’s used in automated distribution and
Warehousing. In Combination with computer controlled pallet handling equipment. This
Allows for more efficient retail, wholesale and manufacturing distribution. It is considered a
labor saving system that allows large volume to move rapidly through a process, allowing
accompanies to ship or receive higher volume with smaller storage space and with less labor
expense. Conveyors are able to safe transport materials from one level to another, which
when done by human labor would be strenuous and expensive. They can be installed almost
anywhere, and are much safer than using manually or other equipment to move materials.
They can move loads of all shapes, sizes and weight. Also, many have advanced and safety
features that helps prevent accidents [International journal2012].
2.5 History of belt conveyor
Primitive conveyor belts were used since the 19th century.
Figure 13
In 1892, Thomas Robins began a series of invention which led to the development of a
conveyor belts used for conveying ores, coal and other products.
24
Figure 14Belt conveyor transportation of ores and other packed product

In 1901 Sandvik invented and started the production of steel conveyor belts.In1905 Richard
Sutcliffe invented the first conveyor belts for use in coal mines which revolutionized the
Mining company’s highland Park, Michigan factory. In1972, the French society REI created in
new
in new Caledonia the longest straight belt conveyor in the world, at a length of13.8km.
Hyacinth Marcel Brochette was the concept designer in1957, the B.F.Googrich Company
patented a conveyor belt that it went on to produce as the turn over conveyor belt system. In
corporations the half twist it had the advantage over conventional belts of long life because
it could expose all of the surface area to wear and tear. Mobius strip belts are no longer
manufactured because untwisted modern belts can be made more durable by constructing
them from several layers of different materials. In1970 intrados a Louisiana based company,
registered the first patent for all plastic, modular belting. The longest belt conveyor system
in the world is in Western Sahara. It is 98km (61mil) long from the phosphate mines of
burqa to the coast south of El-Aaiun [ Website, http/www. History of belt conveyor
system]. Other technological advancements including those in maintenance and system
control.
.
25
Figure 15 Belt conveyor, circa 1954(photo courtesy of modern group)

[Website http://wwww. Themhedajournal.org/ content/3q04/ conveyors.php]
5.1.1 BELT CONVEYOR

A belt conveyor system is one of many types of conveyor systems. A belt conveyor system
consists of two or more pulleys (sometimes referred to drums), with an endless loop of Carrying
medium the conveyor belt that rotates about them. One or both of the pulleys are
powered, moving the belt and the material on the belt forward. The powered pulley is the
drive pulley and the unpowered pulley is the idler pulley. There are mainly two industrial
classes of belt conveyors. Those in general material handling such as those moving boxes
along inside a factory and bulk material handling such as used to transport large volumes of
resources and agricultural materials such as grain, salt, coal, ore, sand and over burned and
more [Dr.k.c.AroraVIKAS.Vshinde 2007].
Belt conveyors can be used totransport product in a straight line through changescan also be
used for static accumulation or cartons.

Figure 16 Belt conveyor systems
26
The newly design of belt convayor sistem has many applications .

 Based on Safety
Belt conveyors operate with an extremely high degree of safety. Few personnel are required
for operation and they are exposed to fewer hazards. It is offer less hazards to care fewer
personnel that is inherency in other means of transporting of material. The conveyor
equipment’s itself protected from over load and by built-in mechanism over load and
malfunction by built in electrical and mechanical safety device.
 Based on maintenance cost
Maintenance cost for belt conveyors are extremely low compared to other means of
material handling system .The component parts are usually housed and have very long life
compared with the other. Material handling components usually they needs only scheduled,
inspection and lubrication. Parts are small and accessible, so replacement can be mad in the
site quickly and with minimal service equipment. Also the adequate inventories of spare
parts can be maintained at low cost and required relatively little storage in space.
 Based on transportation distance
The economic benefits of a low operating cost and energy, as well as, some of the
disadvantage of other means of material handling and the advantages of it. A belt conveyor
system means of transportation over increasingly a long distance.
 Based on capacity
In its simpler terms the related hourly capacities of a belt conveyor is the total weight of
materials conveying in one hour with a belt continuously carrying uniform cross section of
materials and traveling uniform speed than other means of transportation system. Abelt
conveyor is a capable of handling an almost unlimited (mass) of Varity of materials.
[CD.TM. Catalogue polines, Lorbran]
 Based on the driving mechanism and speed
The input power of a belt conveyor is electrical power, but most of the industries use a gear
box belt conveyor system. According to Chen honchoing design project of belt conveyor in
2002 E.C, a belt conveyor drive is made up of motor, a speed reducer and drive pulley. The
27
drive pulley is driven by the motor .Two sprockets are put on both of the drive pulley shaft
and the motor, so that they connected by a chain or, chain put around the drive pulley
sprocket and the motor sprocket. The chain is move when the motor is started and the drive
pulley is turned by a chain, because the motor speed is very high, a speed reducer is must be
used, and put between the motor and drive pulley. The motor is connected the reducer with
V-belt or “C” face coupling, and the reducer is connected to the drive pulley with a chain,
so that the drive pulley is turned slowly. But this project design has a limitation. The
limitation of this design project is: High maintenance cost, more lubrication is needed.
During maintenance the down time is more the components of the conveyor are heavy and
difficult to transport. The operation is nosier, the parts are easily damage Based on the above
advantages of belt conveyor and the limitation of chenhonghong design project, we can
design and development of belt conveyor by elimination of complex parts, that is by
remove the speed reducer and a chain, and instead of sprocket and chain use pulley and belt
respectively and optimize motor selection. [Doming R, Alvarez, and penaM.Mcalvo 2007].
28
CHAPTER SIX
6 Methodology
The study is done at GoGo spring water production PLC by considering the standard time
packing process of its production line based on its treatment system.
This research the method of Design and Development of Belt Conveyor System in gogo industry
plc.
Mathematical analysis is done to develop belt conveyer system in the production.
The data are collected by using two ways of data collection. These are primary and secondary
data collection methodologies.
6.1 Primary methodology

Primary data collection is data observed or collected directly from firsthand experience.
 As primary data collection
 Interview with some managers and employees of the company those who are greatly
concerned with packing work
 Producing different forms of questionnaires-it is cost effective, simple and quick way to
gather data that comes straight from the sources.
 Perform scientific experiments in the laboratory class
 Direct observation at each packing line-scientists rely on observation to determine the
results of theories.
 Done case- studies
 Using fly back stop watch, time study bard and meter are use
6.2 Secondary methodology

 As a secondary data collection
 Books and handouts greatly related to the study
 Written materials of the company are used
 Internet
 Used company manual and in download not
Conveyor arrangements
Conveyors have different types of arrangement, such as horizontal, inclined, declined, and
vertical arrangements should be recommended. Belt conveyors can be arranged to follow an
infinite number of profiles or part travels. The arrangement of conveyor is depending on the
materials to transports. Among these conveyor arrangements, in this design the arrangement
29
of belt conveyor is horizontal arrangement is recommended, because of the material are fall
down to use another types of arrangements of a conveyor.
Material characteristics
The successful design a conveyors must begin with an accurate appraisal of the
characteristics of materials to be transported. Attention must be draw to the fact the normal
characteristics of materials are considerably influenced by the movement, slop, speed the
conveyor or the belt that carries the site of materials that can be conveyed is limited by the
width of the belt.
Safety of operation
The operation of belt conveyors is an extremely high degree of safety. Fewer personnel are
required for operation they are exposed low hazards than with other means of transportation
system.
Idlers of conveyor
It is important to select the best idler design for specific condition, since idlers greatly
influenced belt tension, power requirements, belt life capacity and operational success of
conveyors.
Belt tension
Belt tension is not only determining the required strength of belt, but also influence the
design of mechanical parts. Furthermore, the power required to the conveyor is calculated
from the belt tension.
Belt selection
The selection of belt in conveyor is the most important design consideration, since the belt
constitutes a large portion of the initial cost of conveyors.
Durability of system
To design one machine or equipment the services life of the system is take in to account.
Selection of materials It is the especially that the most important factor that the designer should
have knowledge of
the properties of design materials and conveying materials under working condition, some of
30
the important behaviors of design materials are,

strength, durability, flexibility, costly, corrosiveness, weight to cost ratio etc.
Cost consideration
Cost is the most important consideration including in design. The aim of this design is under
all considerations should be to reduce the transportation cost
6.3 Design specifications

Length of conveyor (L) =12m=12000mm
Belt width =80cm=800m
The unit mass of =0.4kg
Mass of each unit conveying items are
Table 4 material to be conveying
Conveying Unit mass (kg)

items(materials)
Bottle of water 4
Empty bottle 1
The maximum unit load from the above table is 4kg with the conveying items Bottle of water.so,
the total volume of water is 6.5litter (0.0065 meter cubic).The density of this conveying item is
615 kg/m3. The design is based on this maximum load and safely conveyed the
other load or other items.
 Idler dimension with the belt width 400mm so that
 Idler diameter=127mm
 Idler length=950mm
 Idler spacing
 Impact idler=0.25m
 Carrying idler=1.2m
 Return idler=3m
 Number of idlers
 Number of impact idler=2
 Number of carrying idler=6
31
 Number of return idle=2

 All diameters of idler are the same.
The maximum lump size related to belt width and for uniform lump size is 50m
6.4 MATERIAL SELECTION

considered while selecting materials.
 Availability of materials
 Suitability of materials for the working condition in service.
 Cost of materials
 Manufacturing processes of materials.
 Mechanical properties of the materials [RobertL.Mott 2003]
6.4.1.1 Material for conveyor roller
The common material for conveyor roller is polyamide (nylon, Capron, zytel, festal) it is a
thermoplastic materials which have the following properties. An excellent toughness
Table 5 mechanical properties of conveyor roller material
Material Specific gravity Tensile Compressive

strength(N/MM2) strength(N/MM2)
Polyamide 1.04- 1.14 70 50-90
E
.
6.4.1.2 Material for pulley
Conveyor pulleys can be constructed using a varieties of materials which the choice of
pulley materials play an important role in determine pulley construction and may substantially
impact overall level of pulley performance in operation .
Some of its properties are - Corrosion resistance
 Heat resistance
 Magnetic response
 High strength
 Easy to fabrication
 Relatively low in cost
32
Table 6 the mechanical properties of pulley material
Condition Modulus Tensile Ultimate Elonga- hardness Density(g/cm

Material of yield tensile tion 3)
elasticity( strength( strength(Mp
Gpa) Mpa) a)
Stainless Shell 200 205 450 20 96HRB 7.74-8.1

steel, annealed
type heat
grade treated
410
6.4.1.3 Pulley Lagging (Cover/Coating)

Lagging is term used to describe the variety of elastomers used to coat the contact surface of
a conveyor pulley.
Lagged pulley surfaces may be plain wrapped (unfinished) or ground to a continuous, semi
smooth surface (rough ground).
Proper selection of a lagging material should address the following variables:
Wear characteristics: The durometer, strength, and abrasion resistance of lagging material
will impact its ability to provide traction, wear properly and hold up to tearing, peeling or
eroding.
Maintenance: The type and style of lagging selected will impact the serviceability of the
conveyor pulley when it requires recoating.
6.4.1.4 Material of shaft
Materials used for shaft should be having the following properties.
 It should have good machinability

 It should have low notch sensitivity factor
 It should have good heat treatment properties
 It should have high resistance propertiesthan steel about 692kg/m3.The mechanical
properties of it shown below.
Table 7 mechanical properties of shaft material.
Yield Ultimate tensile Modulus of Hardness
33
strength(Mpa) strength(Mpa) elasticity(Mpa)
1150 1400 172 170
6.4.1.5 Material for frame

The materials of frame is should be high load resistance and damping characteristic. Grey
cast iron is the most commonly used materials for any machine frames, since it has a
damping characteristics. Grey cast iron is the most commonly used forms of cast-iron. Its
graphite flakes gives it its grey prance and name.
6.4.1.6 Material for bearing
Bearings are made from polyurethane (duthan, texin,) it is a thermoplastic material. It has
high toughness, abrasive resistance, impact resistance materials and it has good dimensional
properties, self-lubricating characteristics and low in cost. The mechanical properties of this
material are:
Table 8 mechanical properties of bearing material
Material Seismic Tensile Compressive

gravity strength(N/MM2) strength(N/MM2)
Polyurethane 1.21-1.26 35-60 25-80
6.4.1.7 Belt material and belt type

Belt materials very wide ranging from polyester covered with rubber and plain or coated
canvas to woven wire or steel rubber. Produce a wide variety of conveyor belt analysis uses
the highest quality of material. Belt can be manufacture from leather with different covers.
The ultimate tensile strength of leather belt from 21 to 35 Mpa and factor of safety may be
taken as 8 to 10.
Table 9 mechanical properties of belt materials.
Belt material Density(kg/m3) Modulus of Ultimate tensile

elasticity (Mpa) strength(Mpa) Coefficient
34
friction for CI
(steel pulley)
Leather 1000 140-315 21-28 0.25-0.3
Canvas 1220 490-1400 35-521 0.20
Rubber 1400 910-1470 6.5-10.5 0.3
Balata 1100 1140-1840 8.0-13.0 0.32
[International journal2004]
Figure 17 conveying belt
6.4.2 Selection of Belt and Criteria of Selection

In selecting an optimum belt for a given application it is necessary to consider the following
parameter
 Tensile strength of the belt
 Load supporting
 Number of plies
 Pulley diameter
 Gauge of cover required
Table 10 designation and characteristics belt yarns
Designation Basic material Characteristics
P Nylon or synthetic yarns Very good tensile strength

and adhesions
Moderate elongation
E Polyester or synthetic yarns Very good tensile strength

and adhesion.
Good impact resistance
EP Very good tensile strength

Polyester-nylon or synthetic and adhesion
35
yarns Good impact resistance

Very good impervious
moisture and
adhesion
This belt is made of the following belt width, tensile strength, and number of plies, cover
thickness, belt carcasses, and belt carcasses weight belt carcasses thickness cover grade and
its weight.
Table 11 belt class and its mass cover thickness
Belt Belt Numb Tensile Mass of belt Belt Cover

class width(M er of strength(N/ carcasses(kg carcasses grade(H Mass of
M) plies MM) /M2) thickness( R) cover(kg/
MM) M2)
EP8 800 4 80.0 6.4 5 2.5 1.17

00
36
CHAPTER SEVEN
7 DATA ANALAYSIS
7.1 Analysis of Belt Dimension, Capacity and Speed
7.1.1 Belt Speed
A number of factors should be considered to determine the correct conveyor belt speed. This
including the material size, the arrangements of the conveyor, the degradation of materials
during loading and unloading (discharging), belt tension and power consumption.
The belt speed can be calculate as
V=πdN (1)
Where, V=belt speed in m/s
d=roller diameter in mm
π=pi
N=revolution in rpm
7.1.2 .Belt Capacity

For a maximum efficiency conveyors should be operated fully loaded at a maximum
recommended speed. The belt capacity dependent up on these inter-related factors.
 Belt width
 Belt speed
 The density of conveying materials
 Surcharge angle and repose angle
 The cross-sectional area of the belt
The belt capacity is expressed in ton per hour (T/hr.) or in kg/second. [14]
Generally the belt conveyor Capacity can be calculating as follows.
Q=3.6.A.V. ⍴
(2)
Where, Q=Belt capacity in (kg/s)
37
A=the load cross-sectional area in (m2)

V= the belt speed in (m/s)
⍴ = the density of conveying materials in (kg/m3)
In order to arrive to determine the conveyor capacity using the other alternative relationship,
this is given by:
V=Q/ ⍴ (3)
Where, V= the specific volume required to conveyed in (m3/hr.)
Q= the peak tonnage quantity in tone/hr. or kg/s
⍴ = density of the material in (kg/m3)
The specific volume and the required cross-sectional load area are related by
V=3600.A.v.k (4)
Where, v= belt speed (m/s)
A=the load area in (m2)
The factor k is reducing factor used for inclined and declined conveyor, but a horizontal
conveyor the reducing factor (K) is negligible. The cross-sectional area of a flat belt is
depending on the surcharge angle, which is the angle of repose of a material in dynamic
motion. This angle is based on the follow ability of the materials. The angle of repose (∅) at
rest is different from the angle of repose in motion (∅m) and the relation is given by:
∅m =0.7∅
(5)
For the characteristics of material follow ability is uniform size with the repose angle at
motion is equal to 19°.From this to determine the cross –sectional area of the belt. The cross
section area of the belt (A).
38
Figure 18 cross sectional area and angle of repose for belt conveyor
Pulley face width=B+2.edge clearance
Where, The edge clearance for a belt width 800mm to 1000mm is75mm
B=the belt width in mm
H= the height in mm
When ∂ = ∅m
∅m = angle of repose at motion in (°)
A1= the cross-sectional area of the belt section one (m2)
A2= the cross- sectional area of the belt section two (m2)
A = the total area of the belt which is =A1+A2 in (m2)
The cross sectional area of section one and two is can be calculated by using right angle area
formula as follows.
A1=B1*h/2 (6)
A2=B2*h/2 (7)
But h is can be determine by the function of repose angle (∅m)
h=h1=h2= B1.tan∅m where ∅m =19°
B1=B2 =B/2 and B=the belt width its volume is 800mm=0.8m from the specification.
B1=B2=0.4m
H=0.4m.tan19°=0.138m.
A1=A2=B1h/2 =0.4m*0.138m/2=0.0276m2
A=A1+A2=2A1=2A2=2*0.0276m2=0055m2
From equation (2) the capacity of the belt conveyor is given by
Q=3.6.v.A.⍴ (Kg/s)
Where, Q= capacity of belt (kg/s)
A=area of the belt (m2)
V=belt speed (m/s)
⍴=Density of material (kg/m3)
Belt capacity (Q) = maximum load * safety fact
39
Q = 4Kg*1.8 =6.4kg
From the specification the capacity (Q) =6.4kg/s and the belt speed can be determine by
using
V= m/s
⍴
V= ,V=2m/s
,
From equation (4) the specific volume and the require cross-sectional load area can
be determine by
V=3600A.v (m3/Hr)
Where, V=is the specific volume required to conveying (m3/hr)
v=belt speed (m/s
v=3600*0.055m2*0.05m/s=11m3/hr.
The mass of the material (Mm) or live load per meter (unit length) in kg/m can be
calculate by using
Mm= = 0.278 (8)
Mm =36 kg/m
7.1.3 Belt Tension

In order to calculate the maximum belt tension and the strength of the belt is required. It is
first necessary to calculate the effective tension.
The effective tension (TE) is a function of many factors. The
most common factors are the length of the conveyor, the weight of the moving parts, the belt
idles, the weight of rotating idle parts and the frictional force involved against the movement
of belt and the load it is carrying. To determine the different forces involved the following
relation is must be applied for horizontal belt conveyor.
TE=TX + TY (9)
40
Where, TX=the tension component for the empty belt.

TY= the tension or the force required to move the load on the conveyor length.
TX is the force necessary to move the only the empty belt along the conveyor length (L). the
weight of the rotating parts, such as belt, idlers, pulley and the coefficient of rolling friction
between the belt and idlers. Ty will be depends on the conveyor length, the rate of loading
and the coefficient of friction between the belt, and idlers and the mass of moved parts. TX
and Ty are given in Newton (N) is given by:
TX=9.81.L.FB.P (10)
TY=9.81.L.FL.M (11)
Where, L is the conveyor length and equal to the center to center distance of pulley’s is in
plus 45mm(0.045m) for normal driving condition .FB and FL the friction coefficient for the
empty and loading belt respectively and their values being generally take to be around
0.03. Where, P is the weight of the moving parts in kg/m
M is the weight of the material load in kg/m and given by M=0.278* .

[21TataMcGrawhill2007].
The mass of the moving parts can be determine from the standard table and apply
an interpolation method to determine the unknown mass.
Table 12 mass of the moving parts
Belt width(mm) Mass (kg/m)
Medium duty 127 mm idles, Moderate belt
400 22
450 25
600 36
750 46
900 55
[http:/www.ckit.co.za secure belt conveyor]
For this design the belt width is 800mm, so that to determine the mass of the moving parts
by applying the interpolation methods. For the medium duty, 127mm idlers and moderate
belt and belt width 400mm the mass of the moving parts can be determine by:
41
750=46
800=m
900=55
M=49kg
Where, m is the mass of the moving parts and the value is equal to P value. The mass of
material (Mm) is equal to M which is the live load per meter it is already determine from
equation (8) its value is 36 kg/m. then calculate the tension on the empty belt and the tension
on the load belt and the total or effective tension.
The empty load of the belt (TX) is given by
TX=9.81*L*FB* P
Where, L=12.045m
P=49kg/m
FB=0.03
TX=1707N
The tension for a loaded belt is TY which is given by:
TY = 9.81*L*FL*M,
Where, L = 6.045m
FL = 0.03
M = 36kg/m
P = 49kg/m
TY =1256N
The maximum effective tension of the horizontal belt conveyor (TE) is given by adding the
empty belt tension (TX) and the loaded tension (TY) of the belt
TE=TY+TX
TE=2963 N
42
Totalemptyfriction=Fe(L+tf)*W*9.81e-3 (12)
Loadfriction=Fe(L+tf)* *9.81e-3 (13)
Returnsidefriction=Fe*W*L*0.4*9.81e-3 (14)
Where, eTf = Terminal friction constant (60m)
W = weight of the material and belt
Fe = equipment friction factor (0.03)
L = Length of conveyor
V = belt speed
Q = belt conveyor capacity
From equations (12)
 Total empty friction = 28.8N
 Load friction = 4.22N
 Return side friction = 2.052N
Total friction force = total empty friction +load friction +return side friction =
35.072N
The total power losses due to friction are:
Pl= Tf*v/1000
Where,
Pl = power losses due to friction
Tf = tension n due to friction
P1=
7.1.4 .Design of Roller

The roller is support belt and facilities easy to as well as free rotation of the belt conveyor in all
direction.
The correct choice of roller diameter must take in to account the belt width. From the
relation of the maximum belt speed, the roller diameter able to determine the relative
revolution per minute (rpm) by using the formula
N= rpm
43
Where, d= the core diameter of the roller (mm)

V= the belt speed (m/s)
N= revolution in rpm
The belt width is designed 800mm, the belt speed calculated from equation (2) and its value
is 0.05m/s and the roller diameter 127mm. The basic belt length (L) is =2* length along the
conveyor route.
L=2*12m=24m
The diameter of rolled belt (D) is calculate as follows
√
D=
(15)
Where, d= bore diameter
L=basic belt length
T=thickness of belt
D= roller diameter
√
D= = 320m
7.1.5 Design of Driving Belt

There are many types of driving mechanisms, but generally it can be grouped in to two.
These are flexible and non-flexible (rigid) types of driver. The flexible driver mechanisms
Are belt, chain and ropes and the rigid driver mechanisms is gear.
The importance of flat Belt drives overall others are:-
o It is relatively cheap and easy to maintain
o When it worn out they are easy to replace
o They do not required precise alignment of shaft
o The design is simple and inexpensive.
44
o They can be used for long center distance up to 15m. [Robert Mott 2003]
o High efficiency
o High machine performance
o Low energy consumption
o Low cost
o Energy and cost saving- Energy consumption reduced by4%-6%
o Reduced operating cost
o No vibration
o High machine speed
TE is a result of the difference between the two
Standards of the belt located on either sides of the pulley. These sides are the
Higher tension subjected is as refers to as tight side and the other side is slake
Side. The above two tensions are denoted by T1and T2 respectively. They are
Related to each other by the formula:
Where, The coefficient of friction between the drive pulley and the belt
For a leather belt the value of is determine as
=0.54-(42.6/152.6+v)
Where, v=belt speed
=0.26
The wrap angle ( ) in radians the arc of contact on the drive pulley and the value is 186.1°.
e is the base of naperies logarithms=2.718
The driving factor (k) is determine by
K= 1 (17)
K=1.8
The drive (wrap) factor is mathematical value used in the determination of effective belt
Tension (TE) that can be dependably by the drive pulley. The TE that can be developed is
Governed by coefficient of friction between pulley and the belt and the values of the slake
Side and the tight side tension.
TE=T1-T2 (18)
45
T1=TE+T2 (19)
` T1=TE .k (20)
The tension in the tight side (T1) is determined from the above relation.
T1=TE*k
Where, K=1.8
TE=2963N
T1=2963N*1.8=5334N
The tension on the slake side (T2)
T2=T1-TE
T2=5334N-2963N=2371N
The recommended maximum tension rate or working strength of the selected belt is
80N/mm with the belt width 800mm and number of ply four.
Tmax=80N/mm*800mm/4=16000N is the maximum working tension.
F.S= =2
The percentage ratio of the tight side tension and the working tension used to determine the
Minimum pulley diameter.
100% (21)
= = 34%
Pulley diameters:
The minimum pulley diameter recommended for particular belt depends up on three
Factors.
1. Carcass thickness-
o The wire rope diameter in the case of steel cord belts.
o The overall thickness of all plies plus the rubber skins between plies in the case of
plyType belts.
o The overall thickness of the thick woven fabric separating the top and bottom covers
inThe case of solid woven belts.
46
2. Operating tension- the relationship of operating tension of the belt at the particular
Pulley to the belt allowable working tension.
3. Carcass modulus- the relationship between the elongation the carcass and the resulting
Stress. [Technical manual Dunlop conveyor 2012]
Based on this and the % ration of the tension, which is 30% up to 60% the specified
Recommended minimum pulley diameter, are as follows as:
Driven pulley=500mm, Drive pulley=400mm [Fener Dunlop 2009]
7.1.6 Determination of Power and Motor Selection

The longer length of the belt the more the power required for the conveyor.
To find the required power of the motor that used to drive the system is given by
P= (22)
Where, P= power required to drive the system (KW)

V=belt speed (m/s)
TE=effective tension (N)
P=2963N*2.8m/s/1000=8Kw
Based on this power to select the appropriate types of motor that can be drive the system,
The types of motor which is selected permanent magnet servo motor with the following
parameters.215mm frame at, 8.6 Kw, 1500rpm, 55mm unit price us$200.0 which is equal to
4115.3 birr, model number 215YSA15F number of poles is 8, speed constant, and function
Drive and control.
Figure 19 AC permanent magnet servo motor

The efficiency of motor power is given by
( )( )
Efficiency η= *100%.
( )( )
47
η=
To determine the maximum belt tension at start up and the appropriate belt strength
depending on the following points.
o Installed motor power
o The belt speed
o The belt width
The maximum belt tension at start up can be calculated with. [Technical manual Dunlop
conveyor2012]
F=
(23)
Where, F= the belt tension at start up (N/mm)
P=motor power (KW)
V=belt speed (m/s)
B=belt width (m)
F= =12.3KN/m
The appropriate belt strength easily calculated by the following formula
Ts= (24)
Where, η=splice efficiency and its value is determine based on the number of plies and ply
Steps. For number of plies is 4and 3ply step the value is 0.75.
Ts=the tensile strength (N/m).
Ts= = 88.56KN/m
The output revolution is can be determine based on the pulley diameter and belt speed and it
can be calculated as follows.
V= (25)
Where, V=belt speed in m/s
48
D=pulley diameter in mm
N =revolution in rpm
From the above equation to be evaluate the revolution
N= (26)
N= =105.66rpm.
The extra diameter of pulley to provide the purpose of lagging is 6mm

For designing a flat belt drive involves including the following information.
o Power
o Speed of the drive unit
o The speed of the driven unit
o The desired center distance, and
o The service condition.
So based on the input data the following parameters are Calculated as follow.
Input data
o Power=8.5KW
o The allowable tensile strength of the material=1.7Mpa
o Driven pulley diameter=500mm
o Drive pulley diameter=400mm
o Revolution of motor shaft=1500rpm
From= (27)
n2= = 1200 rpm
The velocity ratio v = =10 m/sec
The centrifugal stress (σc) =
Where w = specific weight of belt material

( )
σc = ( = 0.102 MPa
The power transmission /mm2 areas, p/mm2 σ1
49
P/mm2 = , where k = = 0.598
P/mm2 = =0.096 KW/mm2
The areas of cross section of the belts
Area, A = = = 83.33 mm^2
Then the belt width will be, a= b*t

Where, t =10 mm from the standard.
b=
The distance between two pulley (c) is depends on the service condition. So for this
Application c =1000 mm, then the length of the belt, L can be determine by the relation,
L =√( ) ( ) ( )
180+2sin-1( )* =180+2sin-1( ) =3.1916rad
180-2sin-1( )* =180-2sin-1( ) =3.041rad
L =√( ) ( ) ( )
L =√( ) ( ) ( ) = 3403.59mm
50
=3.40359m
The power transmitted capacity of driving belt is:
P = (T1-T2) V
P= (7704-3424)10
=42800W
=42.8KW
The factor of safety for the driving belts is the ratio of the allowable tensile strength of the
Belt to the maximum shear stress. According to the maximum shear stress theory
τmax =0.5*Sut
τmax=0.5*1.7N/mm2=0.85N/mm2
F.s=
7.1.7 Design of Shaft

Considering all the resistances including the wrap and bearing resistances to get the torque
from the formula
P= (28)
Where, P=power in kW
T= torque in Nm
N= revolution (N=76.4 rpm output)
T= (29)
T= =1070Nm=1.070KNm
The determination of force on the shaft of pulley is shown below. For a pulley weight of198.9N
51
(20.3kg)
W (pulley weight)
Resolving horizontal and vertical force components
FH=horizontal force component
FV= vertical component
FH=T1*cos6.1° +T2*cos6.1° (30)
FV=T1*sin6.1° +W- T2*sin6.1° (31)
From equation (26) the vertical component force is determine.
The value of T1 =5334N and T2=2371N
FH=5334N* cos6.1°+2371N *cos6.1° =7.661KN
FV=5334N* sin6.1°+198.9N-2371N* sin6.1°=514N
Determination of horizontal load on the pulley shaft the length of the shaft is 1500mm,
which.is 1.5m
The horizontal load acting on the point ,B,RHB equal to the horizontal load acting on the
point ,C RCH and the value is equal to half of the horizontal force FH .That is
52
RBH = RVH =
RBH=RVH=
The other reaction force can be calculated using the relationship between forces and bending
moments.
Taking the moment at point, A which is MHA=0
MHA=RBH*0.275m+RCH*(0.275+0.95)-RDH*1.5m.
0=3.83KN*0.275m+ 3.83*(0.275+0.95)-RDH*1.5m.
1.5RDHm=5.745KN
RDH=
Therefore the value of the reaction force RAH is equal to the value of the reaction force RDH
which is 3.83KN.
Determine the horizontal moment, Using the above horizontal forces can be determined the
horizontal moment as follows.
The moment at B,MBH=RHB*0.275m

MBH=3.83KN*0..275m=1.052KNm
Moment at C,MCH=RCH*0.275m=3.83KN*0.275m=1.052KNm.
Determination of Vertical Load
53
Point load at B, and at point C, are represent by RBV and RCV respectively. And its value can
be determined from the vertical load FV.
RBV=RCV= which distribute load of FV.
RBV=RCV= .
MAV=0
=RBV*0.275m+RCV*(0.275+0.95= RDV *1.5m.
=0.257KN*0.275m+0.257KN*(0.275+0.95)-RDV *1.5m. =0
=0.406KN=1.5RDV.
RDV=
The value of RAV is similar to the value of RDV since it is distribute load which is 0.3269KN.
Calculate Vertical moment
54
Moment at point B,MBV=RBV*0.275m
=0.257KN*0.275m=0.07068KNm.
Moment at C, MCV=RCV*0.275m
=0.257KN*0.275m=0.07068KNm.
Resultant moment at point B is denoted MBR=√ (MBV2+MBH2).
MBR=√ ( ) ( ) =1.055KNm
Resultant moment at C,MCR=√
MCR=√ ( ) ( ) =1.055KNm
.
Therefore the value of MBR=MCR=1.055KN-m.
Then calculate the equivalent torque (Teq)
Teq=√(( ) ( ) )
Where T=torque=1070Nm=1.070KNm
Kb=bending service factor=1.5
Kt=torque service factor=1.25 then equivalent torque Teq is
55
Teq=√(( ) ( ) )=2.65KN-m.
The allowable (maximum) shear stress (τs) = (32)
For the maximum shear stress is calculated from the minimum of 30% of the yield strength
and 18% of the ultimate tensile strength of the shaft material times 75%.
Take the minimum of
=0.3Syt, Sty=1150Mpa
=0.3*1150Mpa=345N/mm2
=0.18Sut, Sut=1400Mpa
=0.18*1400Mpa=252N/mm2 which is the minimum values.
Then τmax=0.75*252n/mm2=189N/mm2.
Determine the shaft diameter (d)
√
d= (33)
d=41.48mm but for the standard manufacturing the shaft diameter is

50mm
Factor of safety (F.S) = , since the shaft material is ductile
F.S= =3
7.1.8 Selection of Bearing

Bearing is a mechanical element that permits a relative motion between two parts. Such as
shaft and housing, with minimum friction. The main function of bearings is:
o The bearing ensures free rotation of the shaft or axle with minimum friction.
o The bearing supports the shaft or axles and holds it in correct position.
o The bearing takes up the forces that act on the shaft or axle and transmits to the
frame (foundation).
There are so many types of bearings but for this design select the rolling contact type ball
56
bearing. Since the rolling contact bearing have the following advantages over the sliding
bearing.
in service.
A ball bearing consists of an inner race which is mounted on the shaft or journals and
an outer race which is carried by the housing or casing, in between the inner and
outer race anal is placed.
Figure 20 Radial ball bearings and housing

When a ball bearing supports only a radial load (WR), the plane of rotation the ball is
normal to the centerline of the bearing.
Table 13 application and life of bearing
Application of bearing Life of bearing in hour
Machine working intermittently, whose break

down would 8000-12000
have serious consequences, e, and g.auxillary
machinery in
57
power station, conveyor plant for flow

production, lifts,
Cranes for piece good and machine tools used
frequently.
[Gupta, J.K.A2005]
Table 14 Xand Y factors for ball bearing
Fa/cCo Fa/Fr <e Fa/Fr>e e
X Y X Y
0.025 1 0 0.56 2.0 0.22
0.040 1 0.56 1.8 0.24
0.070 1 0 0.56 1.6 0.27
0.130 1 0 0.56 1.4 0.31
0.250 1 0 0.56 1.2 0.37
0.500 1 0 0.56 1.0 0.44
Table 15 dimension and static and dynamic load capacity of ball bearing
Dimension(mm) Basic load rating Designation

D D B C Co 61809
45 58 7 6050 3800 16009
- 75 10 15600 9300 6009
- 75 16 21200 12200 6209
- 85 19 33200 18600 6309
- 100 25 52700 30000 6409
- 120 29 76100 45500 6509
50 65 7 6240 4250 61810
- 100 21 43600 2500 6211
1. Determine the radial and thrust force the value from the calculation:
Fr=7.661KN
Fa=514N
Shaft diameter=48mm
2. Determine the value of X and Y which is the radial and thrust factor
respectively.
3. Calculate the equivalent dynamics load (Pe)
58
Pe=X*Fr+y*fa
Where from the table, X=0.56 & Y=1
Pe=0.56*7661N+1*514N=4805N
4. Make a decision the excepted bearing life is 8000hr.
L10= =24792 million revolution.
5. Calculate the dynamic load

C=P (L10)1/3
C=4805(247.92)1/3=30185.4N
6. Select the types of bearing for this application bearing number 6309(C=30185N)
is suitable.
Bore diameter 45mm and outside diameter=85mm.
Design of bearing cap and bolts
Depending on the ratio of the length of bearing to the diameter, the following parameters
determine from the table.
= 0.223 Where, B = bearing length
D = outer diameter of bearing

absolute viscosity(Z) = 0.06 kg/ms
ssure(p) = 12.6Mpa
0.233
μ =( ) ( )+K
= ( )( )+0.23= 0.233
When split bearing is used, the bearing cap is tightened on the top. The load is usually cared
by the bearing not the cap. For the cap and the holding down bolts must be designed for full
load. The cap is generally regard as a simple supported beam, supported by holding down
59
bolts and loaded at the center.
Figure 21 bearing cap
W=load supported at the center

a= the distance between the holding down bolts
l= the length of the bearing and
t=the thickness of the cap
The maximum bending moment at the center is
M= ( ) ( )=1.02m
The section modulus of the cap

( )
Z= = 1965.51mm3
= 0.00196m3
Therefor the bending stress
σb = 537.24KN/m2
= 0.537N/mm2
t=√ =√ =23.7mm
The deflection of the cap should be limited to about 0.025mm

In order to design the holding down bolt, load on each bolt is taken 33% higher than the
60
normal load on each bolt. In other words, load on each bolt is taken
, where n is the number of bolts used for holding down the cap. Let dc = core diameter of the
bolt, and σt =tensile stress for the material of the bolt =
(dc) 2*2* σt= from this equation the core
diameter is determine. dc = 17.2mm
7.1.9 Selection of Key

Key is can be defined as a machine elements that is used to connect the transmission shaft to
the rotating machine elements, like pulley, gear, sprocket or flywheel. There are different
types of keys. These are:
o Saddle and sunk key
o Square and flat key
o Taper and parallel key
o Key with and without gibe head
The selection of key for a given application depends on the following factors
1. Power to be transmitted
2. Tightness of fit
3. Stability of connection
4. Cost
For this design to select the sun key, because of sunk key is suitable for heavy application
duty since there is no possibility of the slip around the shaft. It is the positive drive over the
saddle. Sunk key has a square or rectangular cross- section is widely used in practices. The
rectangular cross-section is a flat key. While the selection of the rectangular cross section
sunk key without stress analysis according to thumb rule dimensions as follows.
b= h= L=1.5d
Where, d=shaft diameter=50mm

b=width of key (mm)
h=thickness or height of key (mm)
L= length of key (mm)
61
b=13mm, h= 8mm, L=75mm

Key size=b*h =104mm, key depth=6.0
3.15 Design of Frame
Frame is one of the belt conveyor components and its function is to support all parts and
load s that exert by the system.
Equivalent length of frame
According to Euler’s formula the crippling load for equivalent length of column calculated
as:
Pc=
Where, L is the equivalent length or effective length of the column. The relation between the
equivalent length (L) and actual length (l) for the given end condition is shown in the
following table.
Table 16 end condition and the relation between effective length and actual length
S.NO End condition Relation between effective length(L)and

actual length(l)
1 Both ends hinged 1

2 Both ends fixed ½
3 One end fixed and other end hinged 1/√2
4 One end fixed and other free 2I
Total load =life load + dead load
528Kg +57.82KG =585.82Kg
W = mg
585.82*9.81 =5746.87N
Since there are four pairs of column frame the above load should be distributed equally. So
the load on each column frame obtained by:
Load on each column frame = =718.385N
62
Figure 22 frame of conveyor

Functional length =720mm of support column frame is required for easy operation and
ergonomically for workers. Consider column AB of length L is fixed at both ends effective
length le =
=360mm
Least moment of inertia
I=
I= - =9.145578*108mm
Modulus of elasticity of grey cast iron is 200KN/mm2
Pc=
Where pc= crippling load

Le=effective lengt
Pc= ( )
=139297.8395N
Safe load (Ps) =
Ps =
Ps = 46432.61N
Ps > load on column frame.46432.61N>718.35N, hence the design is safe
63
CHAPTER EIGHT
8 RESULT AND DISCUSSION

8.1 Result
The following results are calculated on the above analaysis.
Belt capacity:- Design of roller:- Belt tension:-
A1=0.0276m2 L=24m m=49KG
A=0.055 m2 D=320mm Tx=1707N
B1=B2=0.4m Design of driving belt:- TY=1256N
H=0.138m T1=5334N TE=2963N
Q=6.4kg/s T2=2371N P1=0.0176W
V=2m/s F.S=2 Design of shaft:-
FH=7.66KN
Power &motor selection:- Design of bearing:- FV=514N
P=8KW Pe=4805N RBH=3.83m
η=93% M=1.0534KNm MBH=MCH=1.052KNm
N=105.6rpm σB=0.537N/mm2 RBV=RDV=0.257KN
L=3.40m
8.2 Discussion
Belt conveyor stop and fault finding
- If the belt is loss speed and the speed monitor is disconnect from the entire system,
check whether the belt is sufficiently tightened and adjust if it is necessary.
- The belt tension is correct if the belt startup immediate at full speed.
64
- In the case of stop, check first whether the conveyor is able to start again.
- If the conveyor is still not able to start without being emptied of materials check the
system.
8.2.1 COST ANALYSIS OF THE BELT CONVEYOR

From the back ground that stated the
number of belt conveyor operator four (4) workers and one conveyor engineer will be
needed. The paid monthly wage of the four operators is 600 birr for each and the total
monthly and yearly paid wage 2400 birr and 28800 birr respectively. The monthly paid
wage of the engineer is 3000 birr and yearly wage is 36000 birr .The total yearly cost of the
operator and the engineer is 64800 birr. In the table below illustrate the list of the parts and
the cost of each.
Table 17 cost of conveyor parts
S.No Part Quantity Unit cost in birr Total cost in birr

1 Belt 1 1300 1300
2 Bearing 4 140 560
3 Shaft 2 350 700
4 Pulley 2 180 360
5 Idler(roller) 9 130 1170
6 Frame 4 150 600
7 Driving belt 1 160 160
8 Motor 1 4100 4100
9 Bolt and nut 10 8 80
10 Vertical stand 8 10 80
Total 39 9110
From the above table the total cost of the material is 9110 birr and for a dual system of a
belt conveyor 18891 birr. The total labor cost is 64800 birr and the manufacturing cost is
5000 birr. Then the total production cost of the belt conveyor is the sum of the labor cost,
the material cost and the manufacturing cost, which is equal to 88355birr
8.2.2 PART AND ASSEMBLING DRAWING
65
figure4. 1roller shaft
ALL DIMENSTIONS ARE IN MM
66
figure4. 2roller
67
figure4. 3horizontal conveyor frame
68
figure4. 4bearing cap
69
figure4. 5conveyor pulley
70
figure4. 6vertical stand of conveyor
71
figure4. 7flat driving belt
72
figure4. 8pulley shaft
73
figure4. 9conveying belt
74
figure4. 10assembling drawing of belt conveyor
75
Table 18 part name
Part Part name Quantity Material

.NO
11 Bolt 10
10 Motor 2
9 Motor stand 2 Gery cast iron
8 Conveying belt 2 Leather with polyester cover
7 Driving belt 2 Leather
6 Driving pulley 2 Stainless steel
5 Driven pulley 2 Stainless steel
4 Roller 18 Polyamide
3 Vertical stand 16 Gery cast iron
2 Shaft 4 Cast iron
1 Frame 4 Gery cast iron
76
CHAPTER NINE
9 CONCLUSION AND RECOMMONDATION

9.1 Conclusion
Industrial attachment sends me to the expected destiny of practical life. By completing this report
I have got overall idea of industrial processes and these may be helpful to know about the
technical and management knowledge of industries and related organizations. This Internship
program will help me in the further challenges of life. I try my best to make this project enriched
with lots of different documents. And also when I stayed in the internship program, I followed
how bottles are produced; how waters are treated; how bottles are washed, filled and capping,
how printer machine print the expiration date of water and also how shrink machine-packing in
its working system. And I have to identify the problems with putting my suggestion for the
solution of those problems.
9.2 Recommendation
All the following recommendations should be addressed for the responsible persons and
company departments if they want to achieve success. However, the recommendations should be
treated as flexible guidelines. So based on the study, I want to recommend that, the company
should use the proposed system to solve all the problems exist in each packing lines of
production department.
To the company:-
I am very much delighted and thankful to the organization for allowing me to do internship in
their organization. I got the platform to have exposed on the industrial processes and enhance my
knowledge and ideas. I am grateful for providing me such opportunity. I would also like to
provide some suggestions and recommendation which I believe that it would enhance the quality
of its applications.
 Improve its salary: - There is no skillful worker like engineers, economists, and the like
in the company, b/c the company pays a little salary for them and also there is no
additional benefit for the employers, and it causes less responsibility for the workers.
Thus the company should improve its salary and hire a skilled manpower. The seal and
level work space changed by machine, because to facilitate the activity the human power
must be substitute by machine. The company will reduce excess cost of employees
especially for the temporary workers hires due to lack of knowing the standard time as
each packing line. The amount of products packs per shift will be increased.
 Proper manipulation of documents: In my view, proper handling of documents based
on some scientific method are needed to accommodate all the files and documents that
would result on better work processes and those files could be easily accessed whenever
required. Unnecessary delay, idle times and bottleneck activities will be reduced.
 Lack of spare parts:-there are no enough spare parts for each machines, because of this
77
the machines will cease during the work time. Therefore the company should ensure the
availability of the spare parts. Most of the time the company not used good performance
operators, therefore this must be corrected.
 Modern managerial system: - on the company there is no a strong link b/n top
managers and their followers, which creates unwillingness on the workers. So to
overcome such problems the company should organize the managerial system.
 Improper use of machines:-during starting and breaking of the machine there is no care;
this leads reduction of the life time of the machines and also creates manual operation of
machines rather than automatic operation. Thus the company should command strict
regulations to machine operators and workers for proper use of machines
To the University/Department:-
I am very much delighted and thankful to the university/department for allowing me to do
internship or practical education in the industry. Next I would also like to provide some
suggestions and recommendation which I believe that it would enhance the quality of education
for students.
 The initiative by the college management for field visit to the respective organization
where the students were undertaking their internship program during internship hour was
highly appreciable. However, due to the problem of our country we didn’t access it thus
establishing corporate relationship with tertiary institutions within the sub-region is very
important.
 The UIL (university industry linkage) should give an attention in placement of students,
rather than throwing them to some place. The UIL should place the students in a place
where they get enough work experience.
78
REFERENCES
1. Alspaughm.A “latest developments in belt conveyor technology”MINExpo 2004,
LasVegas, NV, USASeptember 2004
2. Zazzal and EI-NasharAhmed, Survey of research in modeling conveyor-Based Automated
material handling system in water fabs proceeding of winter simulation conference 2007.
3. EspeelageWwanke E Movement minimization for distance in conveyor flow shop
processing 2013
4. Ananthetal, International journal of advanced engineering technology 2014
5. Dr.k.c.AroraVIKAS.Vshinde, aspects of material handling 2007
6. GooverM.P Automation, production system and computer integrated manufacture 2nd
edition.2000
7. Chakravorty, s.s improving distribution operation: implementation of material handling
system. International journal of production economics in2000
8. Doming R, Alvarez, penaM.Mcalvo (2007).
9. Sople, v, v” (2007) .Material handling equipment exploiting potential in supply chain vol:
10 issue: 10s
10. Feb2010WCB rate setting costs and injury demographics.
11. International journal on engineering technologies2012.
12. Technical manual Dunlop conveyor belting 2012
13. Website, http/www. History of belt conveyor system
14. CD.TM. Catalogue polines, Lorbran, CEMA 5th edition
15. Robert.l.Mott.Machine element mechanical design4thedition.2003
16. Gupta, J.K.A Textbook of Machine Design2005
17. http:/www.ckit.co.za secure belt conveyor
18. Indian journal of engineering and material science vol-11-october 2004.
19. Fabric reinforced conveyor belting thicnical guide. .ISO9001, 2008
20. International journal of advanced engineering Technology.
79
21. Tata McGraw-Hill Hand book of mechanical engineering, 2007.

22. Fenner Dunlop 2009 conveyor hand book, secured
23. Website, Http/www.weight of stainless steel
24. Website, http://www. Globalspec.com/learn more
Controls/powertransmissionmechanical/flat belts.
25. Website,http://www.habasit.com/assets/4312FLY-en-0112
27. website http://wwww. Themhedajournal.org/ content/3q04/ conveyors.php
28. Websitehttp: //www. Automated material handling and storage equipment’s
29 .International Journal of engineering research and technology volume 2, Issue3,
June2014
30 conveyor pulley selection guide 201
80
Appendices
LIST OF ABBREVIATION
 HDP-high density polyethylene
 LDP-low denstiy polyethylene
 Both LDP& HPD are very soft and melt at low temprature.
 PET- PET is polymer that is formed by combining two monomers called modified
ethylene glycol and purified tetra phthalic acid.
 SOLENOID-they are electrical part which used to convert AC to DC
 HOPPER-adevicewhich used to melt PET
 Master batch-color concentrate
 Puenmatic- used to remove additional part that exist the preform.
81

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FACULTY OF TECHNOLOGY

DEPARTMENT OF MECHANICAL ENGINEERING

HOISTING COMPANY :-GOGO INDUSTRY PLC.

DURATION OF INTERN SHIP:- FROM MARCH 01 - JUNE 30, 2017

ADVISOR NAME:-Mr. SRINIVAS K.R.

Name of student Signature Date

_______________ ____________ ____________

Name of Mentor Signature Date

--------------------------- ----------- ---------------------

Name of Supervisor Signature Date

PART TWO ................................................................................................................................................ 20

CHAPTER EIGHT ..................................................................................................................................... 64

Figure 1:- General Organizational structure of Gogo Industry ..................................................................... 3

Figure 3 Diagram of cap injection machine .................................................................................................. 7

1 Background of the hosting company

1.2 Vision of the company

1.3 Mission of the company

1.4 Goal of the company

1.5 The main products /services of GoGo Industry

1.6 The main Customers of Gogo Industry

around Ethiopia like Sudan and Djibouti.

1.7 Organizational structure of GoGo Industry

Casher purchaser mecha chemic electrical

Figure 1:- General Organizational structure of Gogo Industry

Figure 2 process step diagram of cap, perform and bottle production

2 How do I get into the company?

2.1 Sections that I have been working in the company

2.2 Work flow of the section

Figure 3 Diagram of cap injection machine

Mix HDPE, master

Start injecting the Sample and

Weight cats that pass Yes Weight and segregate

Shared defective items use

The caps that pass

Figure 5 Process of cap production

inject pressure 50-7 5Mpa

2.2.2 Preform production area

Figure 6 preform injection machinery

Figure 7General flow diagram of Preform Injection Machine

Process of Preform production

Weigh PET resin and master Switch on the

Set control parameter

Check air and Start injecting the

Does perform Inspect the PET

Shred defective Record the number on the machine

Figure 8 Process of Perform production

Figure 9 The mold Structure of perform injection machine

2.2.3 Bottle production area

Figure 10 the structure of bottle

-performs that produce from PET.

Figure 11 Diagram ofblowing machine

Allow the bottle

Figure 12 Process of Bottle production

Temperature (co) 92 95 100

.high pressure: 2.0MPa

2.3 Work tasks that I have been executed

2.4 Procedures that I have been used while performing tasks

2.5 Challenges while performing tasks

3 Benefits that get from the internship

3.1 In terms of improving my practical skill

3.2 In terms of upgrading my theoretical knowledge

3.3 In order to improving Inter personal communication skill

___